Bicycle Control Apparatus

ABSTRACT

A bicycle control apparatus configured to allow a rider to effect a release gear shift without releasing his grip from the handlebar. The bicycle control apparatus includes a brake lever and a shift lever wherein the shift lever is moveable in a first direction to perform a release shift operation and movable in a second direction toward the handlebar independently of the brake lever.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of application Ser. No.10/906,730 filed on Mar. 3, 2005 entitled Bicycle Shifter.

BACKGROUND OF THE INVENTION

The present invention relates to a bicycle control apparatus, and moreparticularly, to a bicycle control apparatus having a brake lever and ashift lever wherein the shift lever is movable in a first direction toperform a shift operation and movable in a second direction toward thehandlebar independently of the brake lever.

Some bicycle road shifters position a release shift lever behind thebrake lever, the shift lever being actuable inboard toward the bicycleframe to effect a cable unwinding or release operation. A disadvantagefound in some such designs is that although the release shift lever isconfigured to pivot rearwardly toward the handlebar with the brakelever, the shift lever is not configured to pivot rearwardlyindependently of the brake lever. This prevents riders from positioningthe release shift lever closer to the handlebar for gear shifts when notbraking. Accordingly, to effect a release shift, riders must at leastpartially release their grips from the handlebar and reach forward withat least one finger to displace the release shift lever inboard. Otherbicycle road shifters are designed to include a release shift lever onthe inboard side of the shifter hood, also requiring riders to releasetheir grips on the handlebar at least partially to push the lever downwith their thumbs. Therefore, there is a need for a bicycle road shifterthat allows the rider to maintain a grip on the bar while operating agear shift lever to effect a release shift.

SUMMARY OF THE INVENTION

The present invention provides a bicycle control apparatus that allows arider to perform a release gear shift operation, typically a cableunwinding, without releasing his grip from the handlebar. Accordingly,the bicycle control apparatus includes a housing mountable to a bicyclehandlebar, a brake lever assembly and a shift lever assembly. The brakelever assembly includes a brake lever movable toward the handlebar. Theshift lever assembly includes at least one shift lever movable in afirst direction to perform a release gear shift operation and movable ina second direction, toward the handlebar, independently of the brakelever. In one embodiment, the shift lever assembly may include a singleshift lever configured to be movable in the first direction to performboth cable-winding and cable-unwinding gear shift operations. In otherembodiments, the shift lever assembly may include discrete shift leversfor cable winding and unwinding operations. The shift lever according tothis invention is configured to move with the brake lever toward thehandlebar during brake lever actuation. The shift lever is rotatableabout a first axis in the first direction to perform the release shiftoperation and rotatable about a second axis in the second directiontoward the handlebar. The second axis may lie in a plane substantiallyperpendicular to the first axis. In other embodiments of the presentinvention, the second axis need not lie in a plane substantiallyperpendicular to the first axis. Typically the brake lever is rotatableabout a brake lever axis substantially parallel to the second axis ofthe shift lever.

In one embodiment of the present invention, the shift lever includesfirst and second portions. Both portions of the shift lever are movablein the first direction to perform a gear shift operation, the secondportion of the shift lever is movable in the second direction toward thehandlebar. This configuration allows the rider to position the shiftlever closer to the handlebar to perform a release shift operationwithout releasing his grip on the handlebar. The first and secondportions of the shift lever are rotatable about the first axis in thefirst direction and the second portion is rotatable about the secondaxis in the second direction toward the handlebar. The second axis maylie in a plane substantially perpendicular to the first axis. In otherembodiments, the second axis need not lie in a plane perpendicular tothe first axis.

These and other features and advantages of the invention will be morefully understood from the following description of various embodimentsof the invention, taken together with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a perspective view of a bicycle control apparatus mounted to adrop-style handlebar according to one embodiment of the presentinvention;

FIG. 2 is a partial cross-sectional view of a bicycle control apparatusaccording to one embodiment of the present invention;

FIG. 3 is an enlarged partial cross-sectional view of the bicyclecontrol apparatus of FIG. 2;

FIGS. 4 a-4 f are cross-sectional views of a holding mechanism and adrive mechanism at different stages of a cable-release operation;

FIGS. 5 a-5 h are cross-sectional views of the holding mechanism and thedrive mechanism of FIGS. 4 a-4 f at different stages of a cable-pulloperation;

FIG. 6 a is a perspective view of a rider's hand gripping the drop ofthe handlebar, the rider's index finger released from its grip on thehandlebar and in contact with the shift lever positioned behind thebrake lever according to a first mode of shift lever operation;

FIG. 6 b is a perspective view of a rider's hand gripping the drop ofthe handlebar, the rider's index finger deflecting the shift leverinboard to effect a gear shift according to a first mode of shift leveroperation;

FIG. 7 a is a perspective view of the rider's hand gripping the drop ofthe handlebar, the rider's index finger released from its grip on thehandlebar and in contact with the shift lever positioned behind thebrake lever according to a second mode of shift lever operation;

FIG. 7 b is a perspective view of the rider's hand gripping the drop ofthe handlebar, the rider's index finger drawing the shift lever towardthe handlebar according to a second mode of shift lever operation;

FIG. 7 c is a perspective view of the rider's hand gripping the drop ofthe handlebar, the shift lever within the rider's grasp as he twists hishand to effect a release shift operation according to a second mode ofshift lever operation;

FIG. 7 d is a perspective view of the rider's hand gripping the drop ofthe handlebar, the rider's index finger releasing the shift lever towardits rest position behind the brake lever according to a second mode ofshift lever operation; and

FIG. 8 is a top view of a bicycle control apparatus according to anotherembodiment of the present invention with a different axis orientation.

DETAILED DESCRIPTION

FIGS. 1-7 illustrate a bicycle control apparatus 10 mountable to ahandlebar 12 according to one embodiment of the present invention. Thebicycle control apparatus 10 generally includes a housing 18, a shiftlever assembly 21 and a brake lever assembly 23. The housing 18 ismountable to a handlebar 12, typically a drop-style handler found on aroad bike. Looking to FIGS. 1 and 2, the handlebar 12 includes an upperportion 13 extending across the bicycle frame (not shown), a curvedportion 15 extending downward from the upper portion, and a lowerportion 17 extending rearward toward the rider. The curved portion 15and the lower portion 17 are commonly referred to as the “drops.” Thehousing 18 is typically mounted to the curved portion 15 of thehandlebar 12 by a clamp 14 and a bolt 16.

The shift lever assembly 21 pulls or releases a control cable 11connected to gear change mechanism (not shown) to shift between variousgear positions. The gear change mechanism may be a derailleur or otherexternal or internal gear change devices. In this embodiment, the shiftlever assembly 21 generally includes the housing 18, a shift lever 20, atakeup member 22, a holding mechanism 24 and a drive mechanism 26. Inthis embodiment, the shift lever assembly 21 is integrated with thebrake lever assembly 23. The brake lever assembly 23 includes a brakelever 28 pivotable about a shaft 30 or brake lever axis 31. The brakelever 28 is displaceable or movable toward the handlebar 12 to pull abrake cable (not shown) to slow the bicycle. Alternatively, the brakelever assembly may be separate from the shift lever assembly.

Looking to FIGS. 2 and 3, in this embodiment, the housing 18 is mountedto the handlebar 12, a mounting shaft 32 or a first axis 33 extendingthrough the housing 18. The shift lever 20 is biased toward a restposition, preferably tucked behind the brake lever 28, by a preloadedshift lever return spring 38. A first leg 40 of the shift lever returnspring 38 is coupled with the housing 18 while a second leg 44 of theshift lever return spring 38 is coupled with the shift lever 20. Theshift lever 20 includes a first portion 34 rotatably mounted to theshaft 32, and a second portion 36 preferably paddle-shaped for easyreach by the rider's fingers. The second portion 36 of shift lever 20 isconfigured to rotate about shaft 32 along with first portion 34, and torotate about a lever shaft 48 or second axis 49 mounted to the firstportion 34 of the shift lever 20. The second axis 49 may lie in a planesubstantially perpendicular to the first axis 33. Alternatively, thesecond axis 49 need not lie in a plane substantially perpendicular tothe first axis 33, for example, it may be parallel to the brake axis 31(see FIG. 8). The second portion 36 of the shift lever 20 is biased by apreloaded return spring 50 mounted coaxially with the lever shaft 48. Afirst leg of the return spring 50 is coupled with the second portion 36of the shift lever 20 while a second leg of the return spring 50 issupported by the first portion 34 of the shift lever 20. In thisembodiment, the second portion 36 of the shift lever 20 moves with thebrake lever 28 when the brake lever 28 is actuated toward the handlebar.Further, the second portion 36 of the shift lever 20 is displaceabletoward the handlebar independently of the brake lever 28.

The takeup member 22, in this embodiment a spool, is rotatably mountedto the shaft 32. The takeup member 22 includes a groove 52 along itsperiphery for receiving the control cable 11. The takeup member 22 isbiased in the cable-release direction by tension in the control cable 11and, preferably, by a takeup member return spring 54. The takeup memberreturn spring 54 is biased between the takeup member 22 and the housing18. The return spring 54 includes a first leg 56 received in an opening58 in the takeup member 22, and a second leg 60 received in an opening62 in the housing 18.

Looking to FIGS. 2-5 h, the shift lever assembly 21 includes a ratchetwheel 64 having a plurality of teeth 66 about its periphery, while theholding mechanism 24 includes a holding pawl 68 engageable with theteeth 66 to prevent unwinding of the takeup member 22. The ratchet wheel64 is rotatably mounted to the shaft 32 and rotates with the takeupmember 22. The ratchet wheel teeth 66 correspond to gear positions ofthe gear change mechanism. Alternatively, the ratchet wheel 64 and thetakeup member 22 may be formed as one piece. The holding pawl 68 isrotatable about a holding pawl pivot 70 fixed to the housing 18, and isaxially positioned by a retaining ring 72. The holding pawl 68 includesa body 74 and a nose 76 extending from the body 74. The holding pawlnose 76 is biased to engage the ratchet wheel teeth 66 by a preloadedholding pawl spring 78 coaxially mounted to the holding pawl pivot 70. Afirst leg 80 of the holding pawl spring 78 is received in an opening inthe housing 18, and a second leg 86 is supported by the holding pawl 68.

The drive mechanism 26 includes a drive pawl 84 rotatably mounted abouta drive pawl pivot 90 fixed to the shift lever 20. The drive pawl 84 isaxially positioned by a retaining ring 92. The drive pawl 84 includes abody 94, a nose 96 extending from the body 94, and a tail 98. A drivepawl spring 100 biases the drive pawl nose 96 toward the ratchet wheelteeth 66. The tail 98 of the drive pawl 84 rests against a declutchingelement 88, in this embodiment, a declutching wall 88 of the housing 18,when the shift lever 20 is in its rest position.

The shift lever 20 has two modes of operation. Prior to the first modeof operation, the shift lever 20 is biased toward a rest position, thesecond portion 36 of the shift lever preferably positioned behind thebrake lever 28 as shown in FIGS. 1, 2, and 6. To perform a cable releaseshift, both the first and second portions 34, 36 of the shift lever 20are rotated about the shaft 32 in a first direction A for a first shiftmovement toward the bicycle frame. In the shifter embodiment shown, theshift lever 20 may also be pivoted in the same direction for a secondshift movement to pull the control cable 11, the second shift movementbeing greater than the first shift movement. In alternative embodiments,the shift lever assembly 21 may be configured to perform only cablerelease gear changes. To shift gears in the first mode of operation, therider partially releases his grip on the handlebar and uses a finger topush the paddle 36 inboard in direction A (see FIGS. 6 a, 6 b). Duringthe second mode of operation, before performing a shift operation, therider draws the second portion of the shift lever 20 toward thehandlebar 12 independently of the brake lever 28 (FIGS. 7 a, 7 b). Thenwith the paddle 36 in his grasp, the rider twists his hand to perform arelease shift, the shift operation performed by rotating both first andsecond portions 34, 36 about the shaft 32 to release the control cable11 (FIG. 7 c). In the second mode of operation the rider need not removehis hand from the drops of the handlebar to perform a release shift, hesimply twists his wrist to move the shift lever in the first direction.After the release shift, the rider may release the shift lever 20 to itsrest position behind the brake lever 23 (FIG. 7 d) or alternatively maycontinue to grasp the shift lever in preparation for a subsequentrelease shift.

Looking to FIGS. 4 a-4 f, a cable-release operation is described. Beforethe shift lever 20 is actuated, the tail 98 of the drive pawl 84 restsagainst the declutching wall 88 positioning the shift lever 20 in itsrest position (FIG. 4 a). Further, the takeup member 22 and the ratchetwheel 64 are retained in a selected gear position by the holding pawl68, shown engaging a corresponding first tooth 102.

Looking to FIG. 4 b, as the shift lever 20 is actuated by the rider, thelever 20 rotates about the shaft 32, moving the drive pawl 84 away fromthe declutching wall 88 and pivoting the drive pawl nose 96 toward theratchet wheel teeth 66. Looking to FIG. 4 c, as the lever 20 is furtherrotated, the drive pawl nose 96 engages the holding pawl nose 76 causingthe holding pawl 68 to release the first tooth 102 of the ratchet wheel64. Once released, the ratchet wheel 64 rotates about the shaft 32 inthe cable-release direction until the first tooth 102 engages the drivepawl nose 96. This action provides both audible and tactile feedback tothe rider signaling the rider to release the shift lever 20 to completethe cable-release operation.

Looking to FIG. 4 d, as the shift lever 20 is released toward its restposition, the ratchet wheel 64 rotates in the cable-release direction.Further, the holding pawl nose 76 moves toward engagement with a recess104 associated with an adjoining second tooth 106 of the ratchet wheel64, and the drive pawl tail 98 moves toward engagement with thedeclutching wall 88. As the shift lever 20 rotates further toward itsrest position, the drive pawl nose 96 pivots further away from theratchet wheel teeth 66 biased by the drive pawl as the drive pawl tail98 bears against the declutching wall 88 (FIG. 4 e). When the drive pawl84 disengages from the ratchet wheel teeth 66, the ratchet wheel 64rotates in the cable-release direction under the force of the controlcable 11 and the takeup member return spring 54, until the holding pawlnose 76 engages the second adjoining ratchet wheel tooth 106, resultingin a single increment gear shift in the cable release direction. At theend of the cable-release operation, the drive pawl 84 moves back to itsrest position against the declutching wall 88 (FIG. 4 f), positioningthe shift lever 20 in its rest position.

Looking to FIGS. 5 a-5 h, a cable-pull operation is described. Beforethe shift lever 20 is actuated, the drive pawl tail 98 rests against thedeclutching wall 88, positioning the shift lever 20 is in its restposition (FIG. 5 a). So positioned, the ratchet wheel 64 is retained ina selected gear position with the holding pawl 68 engaging the firstratchet wheel tooth 102. As the shift lever 20 is actuated by the riderin the shift direction, the drive pawl 84 moves away from thedeclutching wall 88, positioning the drive pawl nose 96 toward theratchet wheel teeth 66 (FIG. 5 b).

Looking to FIG. 5 c, as the shift lever 20 is further rotated, the drivepawl nose 96 engages the holding pawl nose 76, driving the holding pawlnose 76 out of engagement with the first ratchet wheel tooth 102. Oncereleased, the ratchet wheel 64 rotates in the cable-release directionuntil the first tooth 102 engages the drive pawl nose 96. As the shiftlever 20 is further rotated in the shift direction, the drive pawl 84drives the ratchet wheel 64 in cable-pull direction, as the holding pawl68 free-clutches, the holding pawl nose 76 freely sliding along theratchet wheel teeth 66 (FIG. 5 d).

Looking to FIG. 5 e, as the shift lever 20 is further rotated, the drivepawl 84 further rotates the ratchet wheel 64 in the cable-pull directionuntil the holding pawl 68 engages a next third tooth 110 on the ratchetwheel 64, resulting in a single gear shift in the cable-pull direction.The rider is, of course, not limited to single gear shift increments inthe cable-pull direction. The rider may readily shift multiple gearincrements in the cable-pull direction by simply continuing to move theshift lever in the shift direction until the desired gear position isreached. Audible and tactile feedback is provided to the rider as eachgear shift increment is passed.

Looking to FIG. 5 f, after the desired gear position is reached, therider releases the shift lever 20 causing the shift lever 20 and thedrive pawl 84 to rotate toward their rest positions under the force ofthe shift lever return spring 38. As the shift lever 20 further rotatestoward its rest position, the drive pawl tail 98 bears against thedeclutching wall 88 rotatably biasing the drive pawl 84 away from theratchet wheel teeth 66 (FIG. 5 g). Looking to FIG. 5 h, the drive pawl84 is in its rest position against the declutching wall 88, with thedrive pawl nose 96 disengaged from the ratchet wheel 64.

While this invention has been described by reference to one or morepreferred embodiments, it should be understood that numerous changescould be made within the spirit and scope of the inventive conceptsdescribed. Accordingly, it is intended that the invention not be limitedto the disclosed embodiments, but that it have the full scope permittedby the language of the following claims.

1. A bicycle control apparatus comprising: a housing mountable to abicycle handlebar; a brake lever assembly having a brake lever movabletoward the handlebar; and a shift lever assembly having a shift levermovable in a first direction to perform a cable-release operation andmovable in a second direction toward the handlebar independently of thebrake lever, the shift lever configured to move with the brake levertoward the handlebar during brake lever actuation.
 2. The bicyclecontrol apparatus of claim 1 wherein the shift lever is movable in thefirst direction toward a bicycle frame.
 3. The bicycle control apparatusof claim 2 wherein the shift lever is rotatable about a first axis inthe first direction to perform the shift operation, the shifter leverrotatable about a second axis in the second direction toward thehandlebar independently of the brake lever.
 4. The bicycle controlapparatus of claim 3 wherein the second axis lies in a planesubstantially perpendicular to the first axis.
 5. The bicycle controlapparatus of claim 3 wherein the second axis is not lying in a planesubstantially perpendicular to the first axis.
 6. The bicycle controlapparatus of claim 3 wherein the brake lever is rotatable about a brakelever axis substantially parallel to the second axis of the shift lever.7. The bicycle control apparatus of claim 2 wherein the shift leverincludes first and second portions, the first and second portionsmovable in the first direction to perform the shift operation, thesecond portion movable in the second direction toward the handlebar. 8.The bicycle control apparatus of claim 7 wherein the first and secondportions are rotatable about a first axis in the first direction, thesecond portion rotatable about a second axis in the second directiontoward the handlebar.
 9. The bicycle control apparatus of claim 8wherein the second axis lies in a plane substantially perpendicular tothe first axis.
 10. The bicycle control apparatus of claim 8 wherein thesecond axis is not lying in a plane substantially perpendicular to thefirst axis.
 11. The bicycle control apparatus of claim 8 wherein thebrake lever is rotatable about a brake lever axis substantially parallelto the second axis.
 12. A bicycle control apparatus comprising: ahousing mountable to a bicycle handlebar; a brake lever assembly havinga brake lever movable toward the handlebar; and a shift lever assemblyincluding at least one shift lever movable in a first direction toperform a cable-release operation and movable in a second directiontoward the handlebar independently of the brake lever, the shift leverconfigured to move with the brake lever toward the handlebar duringbrake lever actuation, the shift lever assembly operable in the samedirection by a rider to perform a cable-pull operation and thecable-release operation.
 13. The bicycle control apparatus of claim 12wherein the shift lever is rotatable about a first axis in the firstdirection to perform the shift operation, the shifter lever rotatableabout a second axis in the second direction toward the handlebarindependently of the brake lever.
 14. The bicycle control apparatus ofclaim 13 wherein the second axis lies in a plane substantiallyperpendicular to the first axis.
 15. The bicycle control apparatus ofclaim 13 wherein the second axis is not lying in a plane substantiallyperpendicular to the first axis.
 16. The bicycle control apparatus ofclaim 13 wherein the brake lever is rotatable about a brake lever axissubstantially parallel to the second axis of the shift lever.
 17. Thebicycle control apparatus of claim 12 wherein the shift lever includesfirst and second portions, the first and second portions movable in thefirst direction to perform the shift operation, the second portionmovable in the second direction toward the handlebar.
 18. The bicyclecontrol apparatus of claim 17 wherein the first and second portions arerotatable about a first axis in the first direction, the second portionrotatable about a second axis in the second direction toward thehandlebar.
 19. The bicycle control apparatus of claim 18 wherein thesecond axis lies in a plane substantially perpendicular to the firstaxis.
 20. The bicycle control apparatus of claim 18 wherein the secondaxis is not lying in a plane substantially perpendicular to the firstaxis.
 21. The bicycle control apparatus of claim 18 wherein the brakelever is rotatable about a brake lever axis substantially parallel tothe second axis.
 22. A bicycle control apparatus comprising: a housingmountable to a bicycle handlebar; brake lever assembly means havingbrake lever means movable toward the handlebar; and shift lever assemblymeans having shift lever means movable in a first direction to perform acable-release operation and movable in a second direction toward thehandlebar independently of the brake lever means, the shift lever meansconfigured to move with the brake lever means toward the handlebarduring brake lever actuation.
 23. The bicycle control apparatus of claim22 wherein the shift lever means is rotatable about a first axis in thefirst direction to perform the shift operation, the shifter lever meansrotatable about a second axis in the second direction toward thehandlebar independently of the brake lever means.
 24. The bicyclecontrol apparatus of claim 23 wherein the second axis lies in a planesubstantially perpendicular to the first axis.
 25. The bicycle controlapparatus of claim 23 wherein the second axis is not lying in a planesubstantially perpendicular to the first axis.
 26. The bicycle controlapparatus of claim 23 wherein the brake lever means is rotatable about abrake lever axis substantially parallel to the second axis of the shiftlever means.
 27. The bicycle control apparatus of claim 22 wherein theshift lever means includes first and second portions, the first andsecond portions movable in the first direction to perform the shiftoperation, the second portion movable in the second direction toward thehandlebar.
 28. The bicycle control apparatus of claim 27 wherein thefirst and second portions are rotatable about a first axis in the firstdirection, the second portion rotatable about a second axis in thesecond direction toward the handlebar.
 29. The bicycle control apparatusof claim 28 wherein the second axis lies in a plane substantiallyperpendicular to the first axis.
 30. The bicycle control apparatus ofclaim 28 wherein the second axis is not lying in a plane substantiallyperpendicular to the first axis.
 31. The bicycle control apparatus ofclaim 28 wherein the brake lever means is rotatable a brake lever axissubstantially parallel to the second axis of the shift lever means.